Means for casting concrete beams



Aug. 14, 1956 c, CARLSON ET AL 2,758,353

MEANS FOR CASTING CONCRETE BEAMS Filed NOV. 20, 1953 5 Sheets-Sheet l BY PM lfsxg Aug. 14, 1956 c. R. CARLSON ET AL 2,758,353

MEANS FOR CASTING CONCRETE BEAMS Filed Nov. 20, 1953 3 Sheets-Sheet 2 INVENTORS I 7 C ar/ marlrmlrmlflay/re fuye/le M five/7500 Aug. 14, 1956 c. R. CARLSON ET AL 2,758,353

MEANS FOR CASTING CONCRETE BEAMS Filed NOV. 20, 1953 5 Sheets-Sheet 3 INVENTORS Cbr/ 2 [yr/son, lrrfi/ekdign BY fluyeneMSnenw/r MEANS FOR CASTING CONCRETE BEAMS Carl R. Carlson, Harvey,.Archie R. Gagne,-Homewood, and Eugene M. Swenson, Hazelcrest, lll., ass'ignors to Calumet Flexicore Corporation, a corporation of Indiana Application November 20, 1953, Serial'No. 393,288".

3 @laim's. (Cl. 25-121) This invention relates to means for casting; concrete beams. While the casting means'may be used for easting any desired type of concrete beam, itis particularly useful for casting concrete beams or slabs as disclosed andclaimed in United States Patents 2,299,070, 2,299,071, 2,299,072 and 2,299,111. In these patents there is disclosed an elongated beam of concrete having cored passages therethrough and provided with prestressed steel reinforcement. The invention to be hereinafter disclosed and claimed constitutes an improvement upon the casting mold described in said patents. It will be understood, of course, that the new casting mold may be used for any type of elongated concrete beam.

In United States Patent 2,614,309 issued on October 21, 1952, there is disclosed a casting mold havinga generally U-shaped section, said mold-being adapted to be sprung open for releasing the cast beam. This invention provides a mold which is so constructed that it may readily be opened to release the cast beam. The mold in the present'invention is adapted to be closed to present a substantially smooth unbroken surface of the concrete so that no sensible ridge appears at. the mold break in the cast concrete. Because of therequirement for curing concrete, it is desirable that the mold itself be'as simple as possible so that a large number of molds may be kept in stock for continuous production. The mold embodying the'present invention is provided with means which are simple and eiiective for maintaining the mold in tightly locked position while the concrete is curing, the mold and contents being susceptible to conventional handling as with other molds. The invention also provides means cooperating with the mold so thatwhen said mold and means are in proper cooperative relation, the mold may be opened to release the cast beam or the empty mold may be closed for the purpose of receiving concrete preliminary to the casting of a beam.

The mold embodying the present invention, together with the means cooperating therewith for operating the mold, is so constructed'th'at long beams may be handled effectively. In order that the invention may be understood, anexemplary embodiment will be disclosedin connection with the drawings. The embodiment illustrated is exemplary and may be varied without departing fromthe scope of the invention except asv defined by the appended claims.

Referring now to the drawings, 7

Figure Us a' side elevation of acasting moldembodying the present invention. I 7

Figure 2 is aplan view ofthe moldillustrated in Figure 1, certain parts beingabroken away.

Figure 3 is a perspectiveexploded view of parts of the mold to illustrate the manner in whichthe mold splits.

Figure 4 is asecti'on along line 4-'-4 of Figure (2.

Figure 5 is a' sectional detail along line 5-5 of Figure 2.

Figure 6 is a sectional dtailof apart of amold'wall illustrating the manner in 'whicli the depth-' of 'the mold ma y be changed 2,758,353 Fatented Aug. 14, l$56 'ice Figure 7 is a side elevation along line 77 of Figure 6.

Figure 8 is an end view in section illustrating the supporting means for the mold, the supporting means being ina niold releasing position.

Figure 9 is an end view of the suspension means for the mold. V

Figure 10 is an isometric detail of the mold when closed and showing one bulkhead. I

The mold proper has angle iron, generally indicated by 10, having bottom portion 11 and'side portion 12- joined by rounded corner portion 13. Angle" iron llhas' edge portion 15 extending from rounded corner portion-16. The mold proper iscompleted by flat strip 18, having edge-19'coo'perating with edgeportion 15 of theangle iron. Edges 15 and 19 abu'tand a snugfitbetween the opposed edges is provided. h

Angle iron 10 is rigidly united to channel 22, having web 23 and flanges'24 and 25. The width of web- 23 (the distance betweenfianges 24 and 25) is greatenthan the width of side portion 12 ofthe angle iron. Flange 24 of the channel is about in line with the edgeof-side t2, precise alignment being unimportant. Web portion 23 has part 27 extending below bottom 11- of the angle iron. Mold strip 18 is also permanently attached to channel 32, havingfwebSS and flanges 34-and 35 respectively; Flange 34' is also about-even withthe free edge of strip 13, while the web of the channel has portion 37 extending below bottom 11 of the angle iron when the mold is in assembledcondition, as illustrated in-Figures l and 2, for example.

In casting the beams, itis desirable todefinfe regions at the sides of the beam near the top surface ofthe; beam for accommodating. grout} This region at each-- side may be created by providing liners lll and 41-. Theseliners may be of steel or of any other suitable material-,-- and have suitable width sothat the liners extend downwardly along sides 12 and-18 for desired distances. Liners 40 and 4-1 as illustrated are bent-or shaped to provide longitudinal channels 42'an'd 43 respectively. Liners40 and 41 are rigidly attached to therespeetive mold sides by bolts 45 to 48 inclusive. These bolts have fiat heads with tapered sides and-are accommodated by conical-apertures in the liner body. Thus the bolt heads will be substantially flush with the liners. Suitable nuts are provided to maintain the belts in position. The boltsmay be loosened and removed to permit different liners to be used or to permit a rearrangement o'fthe liners for' 'aecommodating beams havingdifierent width, as will be more fully disclosed later. It is understood that the liners-extend the full length of the form and that bolts-45 to 48 in clusive are disposed at regularintervals alongthe form sides as required. I

Carried by bottom portion 11- of the form outside thereof is angle iron}; generally indicated by 50 and having flanges 51 and SZ respectively. FlangeSZ isin-contact with the exterior surface of part of bottom 11- of the mold. The free end of flange 52" is near the free'end of part 11 of the mold angle iron,- while the cornerof angle iron 50 is back of the free end. Flange 51 extends away from the bottomof the mold. Flange 51 is long enough so that the'free end of the flange is approximately in line with flanges 25 and 35 of channels 22 and 32':

The length of the mold may 'be as great as desired and in practice, may beSOfeetand even longer; At suitable intervals along the length ofthe mold, means are provided on the mold for maintaining' the two parts of the mold in tightly clamped position andadditional means are'provided for causing mold separation to oceur when the clamping means 'are "inoperative; The distance between adjacent mold cl'ar'nping" means will depend 1 upon" such factors as the" thickness of utevarious meld ans and The ends of T 58 are rigidly secured as by welding to plates 62 and 63. Plates 62 and 63 are disposed against the inner surfaces of portion 27 of web 23 and flange 51 of position by bolts 64 to 67 inclusive. Portion 37 of channel 32 has rigidly bolted thereto pin 69 having threaded portion 70 and smooth portion 71. Threaded portion 70 is long enough to extend from flange 51 of angle iron 51? through a suitable aperture in part 37 of the web of channel 32 and somewhat beyond the web, as illustrated in Figures 2 and 4. Threaded portion 70 carries lock nuts 72 and 73 disposed on opposite sides of web portion 37. Threaded portion 70 also carries nut 7 d and oelc nut 75 for providing a shoulder which may engage the surface of flange 51 of the angle iron. Smooth portion 71 of the pin passes through suitable alined apertures in flange portion 51 and plates 63 and 62 and web portion 27. Smooth portion 71 functions as a guide pin and normally in the closed position of the mold will extend beyond web 23 of channel 22. The

closed position will be determined by the adjustment of nuts 74 and 75 and in the proper position of the mold parts, the free edges of the parts of the mold will be alined. As previously pointed out, the gap between the opposed edges is preferably reduced substantially to zero by having the opposed edges in contact. It is clear, therefore, that the two parts of the mold, one part consisting of angle iron and the other part consisting of strip 18, will be movable relative to each other along the length of pin 69.

The locking means are all similar and will now be described. Disposed across the corner formed by flange 35 and web 33 is hearing plate 73a. This plate may have any desired shape and is conveniently rectangular, as illustrated in Figure 3. The angle of inclination to the web is unimportant. Bearing plate 73 is provided with aperture 74a. Web portion 37 of channel 32 is also apertured at 75a. Flange 51 of angle iron 50 is provided with a suitable aperture which is in line with apertures 74a and 75a for accommodating pin 78 having head 79 and threaded portlon 80. When plate 63 will be present, a suitable aperture will be provided through this plate. Where the locking means is not near any pin guiding means or mold guiding means, then plate 63 will not be present and may be replaced by a suitable strip of metal or may be omitted entirely. Bolt 78, as illustrated in Figure 5, when threaded through the various alined apertures, will be disposed at an angle to the plane of bottom 11 of the form. Accordingly, wedge shaped washers 81 may be disposed around threaded part 80 of the bolt so that one side of the washer will be flush against the surface of plate 63 or whatever surface is present, while the other side of the washer may be engaged by nut 82 on the bolt. Bolt 78 has slot 84 extending transversely through, the slot being long enough and wide enough to accommodate tapered wedge 85. The position of bolt 78 is selected so that the short end of wedge 85 may enter slot 84 and then the wedge may be driven home to maintain the two parts of the mold together.

Flanges 24 and 34 may have suitable apertures therethrough along the length of the form for the purpose of accommodating auxiliary angle irons to increase the depth of the mold. Thus referring to Figurese 6 and 7, the top flanges 24 and 34 are provided with apertuers 87 through which bolt 88 may extend. Bolt 88 has a flat head disposed in a conical aperture in part 90 of spacing member 91 having legs 92 resting upon the outside surface of the flange of the channels. Spacing member 01 has side porangle iron 50. These plates are maintained rigidly in 4 i tion 93 lying generally in the plane of the side of the mold and having a suitable aperture for accommodating bolt 94 to support a liner. By disposing the spacing members at suitable intervals along the length of the form on both sides thereof, the liners will extend the sides of the mold and thus permit the depth of the mold to be adjusted. By having mold portions 10 provided with different size bottom portion 11, it is possible to provide molds for beams of different widflis.

Means are provided for handling the mold so that the mold may be filled or emptied, as desired. In general,

this means provides power means for opening and closing the mold, assuming that the locking means on the mold have been disabled.

Referring to Figures 8 and 9, I beam is carried by a hoist. l beam 100 has bottom flanges 101 and 102 from which depend a pair of end supports, of which one is shown in Figure 9. This end support, generally indicated by 103, has fingers or claws 104 extending over. the edges of flanges 101 and 102. Depending end support 103 has slot 106. Riding in slot 106 is pin 107 having head 108 to lock the pin in the slot. Pin 107 carries end plates 109 having ends 110 bent to extend along the outside of webs 23 and 33 of the mold. Lugs 112 and 113 carried by the channel irons for retaining the bulkheads are also large enough to rest upon the top edges of parts 1111 of the end plates when the mold is in a position so that the open end is on top. The mold is supported at the two ends in the manner illustrated in Figure 9 and the mold may be rocked on pin 107 so that the mold may be disposed upside down as illustrated in Figure 8. I

As illustrated in Figure 8, power means are provided for opening or closing the mold when the mold is upside down. It is understood that the wedges for locking the mold will be pulled out of the pins. When the mold is upside down, as illustrated in Figure 8, air cylinder means are provided at spaced intervals along the length of the mold for opening or closing the same. These air cylinders are alike and are operated simultaneously. As illustrated in Figure 8, I beam 100 has attached to bottom, flanges 101 and 102 transverse plate 115. Plate 115 has the ends rigidly supported by reinforcing rods 116 and 117 welded between the ends of plate 115 and the ends of the flanges at the top of I beam 100. Rigidly attached to plate 115 as by angle irons 119 and 120 is air cylinder 121 having a piston not shown inside, the piston being attached to and operating piston rod 122. Air pipes 123 and 124 controlled by suitable valves are provided on opposite sides of the cylinder so that compressed air may be admitted to the cylinder on one side of the piston or the other side of the piston, as desired. Piston rod 122 has end 126 threaded and supports a double claw member, generally indicated by 127. Member 127 has portions 128 and 129 on opposite sides of flange 35 of the form.

The other side of air cylinder 121 is provided with frame 130 having stop portion 131 bent at right angles thereto. Stop portion 131 is adapted to engage portion 27 of the channel when claw member 127 is urged to the left, as seen in Figure 8, to open the mold. Since the greatest force used on the mold is applied in opening the same, this arrangement tends to relieve pivot pins 107 from the shear strain incident to opening the mold. For mold closing movement, part 128 of the claw will engage flange 34 of the channel to move the same to a mold closing position. When this occurs, pivot pins 107 will suflice to maintain the body of the mold against the closing force thereof. If desired, however, additional means for engaging flange 25 to hold the mold against the force necessary to close the mold may be provided. Such means may provide a stop to engage the free edge of web 23.

In order to release the cast beam from the mold, the V greases the mold is in the air. In this position, pins 107 are at the bottom of -slo t 106 so that the entire mold may be turned on pins 107. The mold is turned so that it is upside down with the open part of the mold facing downwardly. Thereafter, the hoist lowers the mold and mold support low enough so that the floor or any suitable supports take the weight of the mold from end plates 103, causing pins 107 to rise in slots 106. By raising the mold sufliciently high, the parts of the mold may be brought into proper relationship with the air cylinder release mechanism, as illuSIrated in Figure 8, so that claw portions 129 and step 130 may be disposed in proper relationship, as illustrated in Figure 8. The air valves are operated to move the piston in each unit to the'left, as illustrated in Figure 8, causing the mold to open. The hoist may now raise the opened mold free of the cast beam. 7 Thereafter, the hoist moves the open mold clear of the beam and the mold is closed by operating the air pressure means. The closed mold is now locked by the wedges previously described, after which the hoist is raised to drop the empty but locked mold to the position illustrated in Figure 9. The mold may now be turned over and deposited on a floor or suitable support. End plates 10 6 are moved longitudinally of the mold so that arms 110 will clear the mold and leave the mold free to be filled with concrete. Referring to Figure 10, there is shown a detail of a locked mold in condition for receiving a concrete The mold has the liners suitably bolted thereto and has bulkheads, one of which is illustrated. Bulkhead 135 has suitable apertures for accommodating the inflatable forms used in the manufacture of the cored beams, and also has small apertures for accommodating the ends of the prestressing rods 137. These prestr'ess'ing rods may bedistribu'ted in any desired pattern and the ends ma be rigidly retained and tensioned by any suitable means. A s an example, the means for engaging the tensioning rods or w'i'res may be as illustrated in the co-periding applications er Gayle B. Price and Paul L. Oswe'iler', Serial No. 304,524, filed August 15, 1952, or Gayle B. Price and Paul L. Osweiler, Serial No; 378,714, filed September 8, 1953. g

The bulkheads are maintained in suitable, position against the tension of prestressingwires. Such means, for example, may consist of arms 139 and 140 rigidly attached thereto, the arms extending away from the bulkhead toward the open end or the form. Arm's 139 and 14!) are provided with suitable apertures for accommodating rod 141 adapted to extend beyond the arms 1 and engage the free ends of the form. It is understood, of course, that rod 141 will be disposed against the free ends of the form to resist the force of the bulkhead when the wires are properly tensioned.

The other end of the form not shown may be provided with similar bulkhead means. When the form is ready to receive the concrete, the mix is poured into the form while the form is vibrated. It is understood that after the beam has been cast and prior to the opening of the mold, the inflatable forms for providing the cored out portions in the beams are removed, these forms being first deflated, and then the bulkheads are removed or the attaching means for anchoring the ends of the prestressing wires to the bulkhead are either removed or cut so that the cast beam may be released when the mold is opened.

While the cut in the mold has been shown as illustrated, it may be disposed at any desired part of the mold. The two-piece form or mold having cooperating edges 15 and 19 as shown may be manufactured in a number of ways. The entire procedure for making the mold may be conventional except for obtaining the cut or slit to provide separate cooperating edges 15 and 19. Inasmuch as these molds or forms may have lengths running into many feet, it is not practical to start with two'pieces making up the mold "orfo r'm' enamel and attempt to machine opposing edges '15 and 19 to fit.

It is preferred to start with "a complete channel for the mold proper, said channel consisting "of bottom I1 and sides 12 and 18. The entire structure illustrated in Figures 3 to 7 inclusive is fabricated and assembled as a one-piece mold except for pins '69. It'will be observed that in the finished two-piece construction, pin 69passes through aligned apertures in channels 23 and 32. In

making the one-piece mold assembly, it is therefore d e si'rable to allow for metal lost in cutting. Assume, for example, that the cut has a width of /4 so that /4" of metal'from original side 18 is lost. This means, there fore, that side 18 together with channel 32 Will'drop Vt" as seen in Figure 4 when edges 15 and 19 are fitted against each other. Accordingly, channel '32 is preferably permanently secured to side 18 of theoriginal one-piece channel in such a way that channel 32' is /2" higher than channel 22 and the apertures in web 37 for acconi modating pin 69 are also drilled /3" higher, all "as seen I in Figure 4. After the form channel has been slit and has resulted in the removal of A of metal, as an example, channel 32 and side 13 can then" be dropped as seen in Figure 4. This will line up channels 22 and 32 and also line up the apertures in web '37 with the apertures in web 23 for accommodating pins '69,

.It is possible to drill an oversize aperture through web 37 somewhat larger than pin 69 and have pins 69 positioned even before the slitting. After the slitting, nuts 72 and 73 may be loosened, if they had been tigh'tgand p-e'rrni't channel 32 to drop into position. Nuts 72 and 73 will thus serve to' rigidly maintain pins 69 in web '33 even though oversize apertures. are provided. In any event, the entire construction as illustrated in the drawing is initially made as one piece and slitting will occur thereafter.

The actual slitting of the original'mold-for'ming channel is accomplished in a simple manner by a poi-table tool consisting of a circular milling cuttei' driven by an electric motor. The milling cutter is provided with two gauges-1 .One gauge maintains the cut at a'predetermined distance with respect to side 18 so that the cut will be along a generally straight line parallel to the free edge of side 18. The other gauge is a' depth gauge for insuring that the milling'cutter will go through the entire thickness of side 18 but will not cut throilgh web 33. The milling cutter has a diameter which is generally smaller than the width of bottom 11 of the form. Thus in practice, bottom 11 of the form may have a width of about 8", as an example. The milling cutter may have a diameter of 3" or 4".

The plane of the milling cutter need not be parallel to bottom 11 but may be tilted with respect to bottom i1 so that the cut may be located as illustrated in Figure 4. As is well known, such cutters have suitable clamping means for rigidly securing them to a motor shaft and in practice, the side of the cutter disc away from the motor will have a motor shaft and clamping nuts extending axially beyond the cutter. Thus the average portable cutting means would not permit the side of the cutter to be brought close enough to bottom 11 to have the cutter parallel to bottom 11 and the cut near corner 16 as illustrated.

If the cut is higher up on side 18, then suflicient clearance may exist for having the plane of the cutter parallel to bottom 11. However, the location of the plane of the cutter with respect to bottom 11 is not important and the outing or slitting may be done at an angle other than to the plane of side 18. This will result in the opposing edges 15 and 19 of the two form parts being at an angle other than 90 to the plane of side 18.

The accuracy of the cut with respect to bottom 11 or with respect to the free edge of side 18 is not important within limits which are easily maintained. Thus if the slit has some tendency to go up or down with respect to bottom 11 along the length of the form, the tight fit between the form parts will in no wise be impaired. It

'is, of course, true that in such case, the two form parts the one piece assembled form on the ground with side I8 horizontal and supporting bottom 11 and channel 22 so that the mold parts will be retained in position after slitting. The mold may also be supported as in Figure 4 with bottom on the ground.

What is claimed is:

l. A separable mold for casting elongated concrete beams, said mold'having a generally U-shaped section, said mold consisting of a generally L-shaped member forming the bottom and one side of said mold and a generally flat member forming the remaining side of the mold, the two mold members having abutting edges when the mold is closed, a channel having a web and two flanges at one side of said mold, said channel having the web thereof disposed along the outside of one side of said mold, a second channel similar to the first dissembled, an auxiliary angle iron outside of and extending the full length of the mold, said angle iron having one portion thereof rigidly attached to the mold bottom near the free edge of the L-shaped elongated member, the angle iron having the other part thereof extending away from the mold bottom and lying between the opposed web portions of the channels, elongated pins passing through the web on the opposed channel on the flat member and other part of the auxiliary angle iron at spaced intervals along the length of the mold and means carried by said elongated pins and cooperating with said channel and angle iron for locking the two mold portions together.

2. A separable mold for casting elongated concrete beams, said mold having a generally U-shaped section, said mold consisting of a generally L-shaped member forming the bottom and one side of said mold and a generally fiat member forming the remaining side of the mold, the two mold members having abutting edges when the mold is closed, a channel having a web and two flanges at one side of said mold, said channel having the web thereof disposed along the outside of one side of said mold, a second channel similar to the first disposed along the outer face of the remaining mold side, said two channels being rigidly attached to the corresponding mold sides, said two channels having portions extending below the mold bottom when the mold is assembled, an auxiliary angle iron outside ofand extending the full length of the meld, said angle iron having one portion thereof rigidly attached to the mold bottom near the free edge of the L-shaped elongated member, the angle iron having the other part thereof extending away from the g mold bottom and lying between the opposed web portions of the channels, elongated pins passing through the web on the opposed channel on the flat member and other part of the auxiliary angle iron at spaced intervals along the length of the mold, said pin having a portion extending beyond the angle iron and web on the opposed channel on the fiat member, one part of such extending pin portion being threaded and having a nut thereon and the other part of such extending pin portion having a transverse slot therethrough and a wedge adapted to pass through such slot and exert force against said channel for maintaining the mold locked.

3. The construction according toclaim 2 wherein the channel portion through which said pin passes is provided with a sloping plate extending between the flange and web with said pin passing through such sloping plate.

References Cited in the file of this patent UNITED STATES PATENTS 

